Modular closet systems and method for constructing a storage structure

ABSTRACT

Modular closet systems and method. A modular closet system includes a plurality of stackable units. A modular closet system includes one stackable unit. Each unit includes a box having a first side panel, a second side panel, a top panel, a bottom panel, a back panel, a substantially hollow interior, and a front opening integral with the substantially hollow interior; and at least one external hanging rod having a proximal end and an opposing distal end. The proximal end is mounted to an exterior surface of a first stackable unit of the plurality of stackable units. The distal end is mounted to a support structure. The method includes providing a plurality of stackable units, arranging the stackable units, providing at least one hanging rod; attaching the first end of the hanging rod to an outer surface; and attaching the second end of the hanging rod to a first support structure.

FIELD OF THE INVENTION

The invention generally relates to storage systems and closet shelving.

BACKGROUND OF THE INVENTION

Current closet shelving systems may have shelves, bracing, and hanging bars which must be custom cut to fit into a specific existing closet, due to the irregularity of dimensions from closet to closet. Once the pieces are cut to measure and assembled, the unit is permanently installed in the particular closet for which it was measured. The walls of each section or compartment of the shelving unit share common wall pieces with each adjacent section, and therefore each section is permanently fixed in its position with respect to other sections. In addition, installation of such a closet shelving system requires a significant amount of measurement and cutting of each piece, which is time consuming and may be prone to errors. There exists a need for a storage system which may be easily assembled and installed and one which may be rearranged as needed by a user.

SUMMARY OF THE INVENTION

The present invention relates to a modular closet system, comprising:

a plurality of stackable units, each unit of said plurality of units comprising a box having a first side panel, a second side panel, a top panel, a bottom panel, a back panel, a substantially hollow interior, and a front opening integral with said substantially hollow interior; and

at least one external hanging rod having a proximal end and an opposing distal end, said proximal end mounted to an exterior surface of a first stackable unit of said plurality of stackable units, wherein said distal end is mounted to a first support structure.

The present invention relates to a method for constructing a storage structure, comprising:

providing a plurality of stackable units, each unit of said plurality of units having a substantially hollow interior defined by a first side panel, a second side panel, a top panel, a bottom panel, a back panel, and a front opening;

arranging said plurality of stackable units, wherein each stackable unit of said plurality of stackable units abuts an adjacent stackable unit of said plurality of stackable units, to form a stacked group of stackable units;

providing at least one hanging rod having a first end and an opposing second end;

attaching said first end of said at least one hanging rod to an outer surface of said stacked group; and

attaching said second end of said at least one hanging rod to a first support structure.

The present invention relates to a modular closet system, comprising:

a stackable unit comprising a first side panel, a second side panel, a top panel, a bottom panel, a back panel, a substantially hollow interior, and a front opening integral with said substantially hollow interior; and

at least one external hanging rod having a proximal end and an opposing distal end, said proximal end mounted to an exterior surface of said stackable unit, wherein said distal end is mounted to a first support structure.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the invention are set forth in the appended claims. The invention itself, however, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings.

FIG. 1 is an illustration of a perspective view of a stackable box or unit, in accordance with embodiments of the present invention.

FIG. 2 is an illustration of a perspective view of an embodiment of a stackable box or unit comprising at least one drawer, in accordance with embodiments of the present invention.

FIG. 3 is an illustration of an embodiment of the present invention wherein a stackable unit may comprise a stabilizing fixture, in accordance with embodiments of the present invention.

FIG. 4 is an illustration of an embodiment of a modular closet system of the present invention comprising a plurality of stackable units and at least one external hanging bar, in accordance with embodiments of the present invention.

FIG. 5 is a flow chart illustrating a method for constructing a storage structure, in accordance with embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Although certain embodiments of the present invention will be shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present invention will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as examples of embodiments. The features and advantages of the present invention are illustrated in detail in the accompanying drawings, wherein like reference numerals refer to like elements throughout the drawings. Although the drawings are intended to illustrate the present invention, the drawings are not necessarily drawn to scale.

FIG. 1 is an illustration of a perspective view of a stackable box or unit 100. The unit 100 may comprise a first side panel 105, a second side panel 110, a top panel 120, a bottom panel 125, a back panel 130, a substantially hollow interior 155, and a front opening 150 integral with the hollow interior 155. The stackable unit 100 may comprise a front face trim or molding 135. The front face trim 135 may provide a decorative border to the opening 150, or may cover unsightly edges of the side panels 105 and 110 or the top 120 or bottom 125 panels. The back panel 130 may provide stability to the stackable unit 100 as well as provide an aesthetically pleasing appearance to a user where the color or texture of the back panel 100 may match that of the other components of the stackable unit 100. The back panel 125 in embodiments of the present invention may provide an advantage for containing small items stored in the stackable unit. A storage device having no backing may be unsightly due to the unmatched appearance of a room wall behind the unit and may have a gap between back edges of the unit and the nearby wall into which small items placed in storage may fall and be irretrievable.

The unit 100 may comprise at least one internal hanging rod 140 which may be disposed inside the hollow interior 155 of the unit 100, which may be used for hanging clothing or other items, for example. The hanging rod 140 may have a first and second end fastened to each of the first 105 and second 110 side panels using at least one mounting device such as a bracket, a hook, a bolt, a nut, a screw, a nail, a dowel, a peg, adhesive, an interconnecting joint, a magnet, and combinations thereof. At least one end of the at least one hanging rod 140 may be fastened in place using a rod holder 145, which is a device configured to hold an end of the hanging rod 140, where a rod holder 145 is fastened to each of the first 105 and second 110 side panels using at least one of the above mentioned mounting devices, and the hanging rod 140 is then secured in place by the rod holders 145.

The unit 100 may comprise at least one shelf 160, where the shelf may be fastened to or supported by the side panels 105 and 110, the front face trim 135, the back panel 130, or combinations thereof. The shelf 160 may be fastened or supported by pegs, knobs, nails, screws, brackets, the like, and combinations thereof which may be reversibly attached to the side panels 105 and 110, the front face trim 135, the back panel 130, or combinations thereof.

FIG. 2 is an illustration of a perspective view of an embodiment of a stackable box or unit 100, comprising at least one drawer 205 slideably attached to the side panels 105 and 110 and substantially disposed with the substantially hollow interior 155 The stackable unit 100 may further comprise at least one hollow pocket or cubby 210, which may be configured to hold smaller items such as shoes or gloves, for example. The cubby 210 may be comprised of solid wood, a wood composite, a laminated wood product, or a combination thereof. The cubby may be attached to or supported by the side panels 105 and 110, bottom panel 125, back panel 130, top panel 120, front face trim 135, or a combination thereof.

FIG. 3 is an illustration of an embodiment of the present invention wherein a stackable unit 100 may comprise a stabilizing fixture 345 configured to be secured to the top panel 120, back panel 130 or a combination of these, to secure or stabilize a stackable unit or units to which the stabilizing fixture may be fastened. The stabilizing fixture 345 may be an L-bracket, a metal strap, a nylon strap, a fabric strap, a wooden block, the like, or combinations thereof, and may be secured to a support structure such as a closet or room wall, wooden stud, bracing, beam, another stackable unit, the like, or combinations thereof. The stabilizing fixture may be configured to secure a stackable unit 100 to a support structure using screws, bolts, nails, anchors, the like, or a combination thereof. For example, a stackable unit 100 may be secured to a wall stud by first fastening a first part of the stabilizing fixture 345 to the top panel 120 by driving screws through holes in the fixture and into the top panel 120, and then fastening a second part of the stabilizing fixture 345 to a wall stud using screws.

The stackable unit 100 may further comprise an external hanging rod 143, wherein the external hanging rod 143 is disposed outside the hollow interior 155. The external hanging rod may be secured to an exterior surface 300 of a side panel 100 or 120 substantially perpendicular to the exterior surface 300, using mounting devices as described above for the internal hanging rod 140 in FIG. 1.

The stackable unit 100 may further comprise at least one hanging cubby 305, which may be hung from an internal hanging rod 140 and disposed with the hollow interior 155, or may be hung from an external hanging rod 143. The hanging cubby 305 may be hung by use of a hanging device 310 such as a strap, wire, hook, and the like, for examples. The hanging cubby 305 may be configured to hold small items such as shoes or gloves and may be comprised of or lined with a soft material such as fabric or felt to prevent scratching of items stored therein.

The stackable units 100 and components thereof as described above may be comprised of solid wood, a wood composite, a laminated wood product, or a combination thereof. The first and second side panels 105, and 110, top panel 120, bottom panel 125, front face trim 135, and back panel 130 may be fastened together to form the stackable unit 100 using fastening devices such as nails, screws, bolts, nuts, adhesives, dowels, pegs, interlocking joints, brackets, or combinations thereof. For example, a stackable unit in an embodiment of the present invention may be comprised of solid wood and fastened together with brass wood screws. In another example, the front face trim 135 on a stackable unit may comprise a wood laminate having a decorative outer surface finish.

FIG. 4 is an illustration of an embodiment of a modular closet system 300 of the present invention comprising a plurality of stackable units 100 and at least one external hanging bar 143. The stackable units 100 may be arranged inside a storage space such as a closet or open room. The stackable units 100 may be arranged such as by stacking stackable units beside or on top of other stackable units. The stackable units 100 may independently each comprise at least one drawer 205, at least one shelf 160, at least one internal hanging bar 140, at least one cubby 210, at least one hanging cubby 305, or combinations thereof. The modular closet system 300 may comprise a plurality of stackable units 100 such as two units, three units, four units, five units, six units, etc. The number of stackable units 100 used may be determined by an individual user's storage needs, by space availability, or a combination of these. In another embodiment of the present invention, the modular closet system 300 may comprise one stackable unit 100, rather than a plurality of stackable units 100.

The stackable units 100 may be arranged in a plurality of configurations to form an embodiment of the modular closet system 300 within the scope of the present invention, where the configuration may be in part determined by the configuration of a storage space where the modular closet 300 may be used. For example, the modular closet system may have a substantially rectangular box-shape for placement inside a conventional closet configuration. In another example, the modular closet may have an angled shape when assemble in a corner of a room or storage area.

The stackable units 100 may be configured to be reversibly fastened together when stacked or arranged in a modular closet system 300. For example, by placing side panels, bottom panels, and top panels of adjacent stackable units flush against each other, adjacent stackable units may be reversibly secured to each other using fastening devices as described above. For example, adjacent stackable units may be secured to each other by using bolts passed through aligned holes drilled though adjacent panels of adjacent stackable units 100, where appropriate sized nuts may be used to secure the fastened connection. Fastening the stackable units 100 together may increase the stability of a modular closet system 300. Using a reversible fastening device may allow for disassembly of the modular closet system 300 without damage to the stackable units 100. The modular closet system 300 may then be reassembled in a second location chosen by a user. The modular closet system 300 may be additionally stabilized or secured to a support structure with the addition of a stabilizing fixture 345 (see FIG. 3) as described above.

The modular closet system 300 may be configured to be free standing, such as in an open room, for example. Since the stackable units are each individual units, shelves or bars of each unit do not depend on those of other units for support. Likewise, side panels, top panels, bottom panels, and back panels are not shared between adjacent units and therefore do not depend on those of other units for support. Therefore, units may be stacked and arranged to stand in a room or storage space without additional support such as braces or fixtures. In addition, the reversible arrangement may allow for the rearrangement of the modular closet configuration as desired by a user.

The modular closet system 300 may comprise at least one external hanging rod 143. A first end (proximal end) of the external hanging rod 143 may be secured or fastened substantially perpendicular to an exterior surface 330 of a stackable unit and a second end (distal end) of the hanging rod 143 may be secured or fastened to a support structure 320, which may support the hanging rod and items hung thereupon. The external hanging rod 143 may be secured to a rod holder at each of the two ends of the external hanging rod 143. For example, the support structure may be a closet or room wall, wooden stud, bracing, beam, another stackable unit, or combinations thereof. In another example, the modular storage unit 300 may be assembled within an existing closet, where an external hanging rod may be secured or fastened between an exterior surface of a stackable unit (of a plurality of units) and a side wall of the closet, where the external hanging rod 143 may provide a spare hanging space which fills a space or gap 325 between the stackable units 100 and a closet wall. The external hanging rod 143 may allow a user to fully utilize the space within a storage area when using prefabricated stackable units 100. For example, a user may stack and arrange the units as desired within a closet and immediately fill the remaining space between the stacked stackable units 100 with an external hanging rod 143 for hanging objects, thus utilizing the entire closet space. The modular closet system of the present invention may have one or more external hanging rods, such as two external hanging rods 143, where each rod may be fastened to a different support structure, such as two different walls in a closet, for example.

A rod holder 145 may be fastened to a cleat 335 which may then be fastened to the support structure 320. The cleat may comprise a board, plank, plate, or similar structure which may be secured to the support structure 320 to provide improved anchoring of the external hanging rod 143. For example, the cleat 335 may be sufficiently long to secure to studs within a support structure such as a wall using sufficiently long screws to anchor it securely, wherein a rod holder 145 may then be secured anywhere along the cleat 335 without regard to how location since the cleat may be sufficiently secure.

FIG. 5 is a flow chart illustrating a method for constructing a storage structure. The storage structure may be constructed inside a storage area such as inside an existing closet, an open, room, a garage, an attic, or a combination of these. Step 500 provides a plurality of stackable units such as those described above, where the stackable units comprise a substantially hollow interior defined by a top panel, a first side panel, a second side panel, a bottom panel, a back panel, and a front opening. The plurality of stackable units may be any number of stackable units depending on the space requirements of a user. The stackable units within each modular closet system may be of the same dimensions, different dimensions, or a combination of these. For example, each of the stackable units may independently have widths of about 24 inches (in), about 30 in, or about 36 in. In another example, each of the stackable units may independently have heights of about 36 in, about 48 in, or about 84 in. These dimension examples are non-limiting and meant only to demonstrate examples of different comparable width and height measurements that may be used with the stackable units of the present invention.

In step 505, the plurality of stackable units are arranged in a desired configuration by a user inside a storage space. For example, stackable units may be stacked or arranged on top of or adjacent to other stackable units to form a stacked group of stackable units. The side panels of adjacent units may be flush against each other to form a block-shaped configuration, where the back panels of the stackable units may be substantially coplanar to form a continuous back surface which may be disposed against a support structure such as a wall of a room or closet. As described above, the stackable units may be arranged to the desire of the user, such as to provide storage in a closet, an open room, or other storage area. The stackable units may be fastened together as described above or may be secured to a support structure using a stabilizing device as described above.

Step 510 provides at least one external hanging rod such as described above for the external hanging rod 143 of FIG. 4. The hanging rod may have a first proximal end and an opposing second distal end.

In step 515, the first end of the at least one hanging rod is attached or fastened to an outer surface of the stacked group of stackable units. The outer surface may be an outer surface of a side panel of at least one stackable unit, where the side panel is an outermost stackable unit in the stacked group and does not have another stackable unit adjacent to the side panel. The first end may be attached or fastened using a mounting device as described above, where the at least one hanging rod may be attached substantially perpendicular to the side panel.

In step 520, the second end of the at least one hanging rod is attached or fastened to a support structure. The second end may be attached using a mounting means as described above. In one example, the hanging rod may be measure, cut, and fastened to a support structure such that the external hanging rod spans a distance between an outer surface of the stacked group and a nearby wall.

In one example of the method described above, a set of six stackable units may be arranged inside an existing closet space. The number of stackable units may be chosen to fit within the closet dimensions. For example, each of the stackable units may have a width of about 24 inches (in.) and a height of about 36 in. The units may be stacked a bottom row of three units beneath a top row of three units inside a closet having a height of about 72 inches or higher and having a width of about 72 inches or wider. A smaller opening of the closet doorway may require that units are each placed inside the closet individually and slid into place between other units. For the present example, if the closet width is substantially wider than the 72 inches, a first end of at least external hanging bar may be attached to an outer surface of a unit on an end of a stacked row, where a second end of the at least one hanging bar may be attached to the closet wall. The space between the outer surface of a unit on an end row and the closet wall may be measured and the at least one hanging bar may be cut to sufficiently span the distance and be securely fastened at both ends. Thus, the open space may be fully utilized with the modular closet system described in this example.

The foregoing description of the embodiments of this invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously, many modifications and variations are possible. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims. 

1. A modular closet system, comprising: a plurality of stackable units, each unit of said plurality of units comprising a box having a first side panel, a second side panel, a top panel, a bottom panel, a back panel, a substantially hollow interior, and a front opening integral with said substantially hollow interior; and at least one external hanging rod having a proximal end and an opposing distal end, said proximal end mounted to an exterior surface of a first stackable unit of said plurality of stackable units, wherein said distal end is mounted to a first support structure.
 2. The modular closet of claim 1, wherein at least one unit of said plurality of units further comprises an internal hanging rod disposed inside said substantially hollow interior of said at least one unit.
 3. The modular closet of claim 1, wherein at least one unit of said plurality of units further comprises at least one drawer disposed substantially within said substantially hollow interior of said at least one unit, said at least one drawer slidingly attached to said first and second side panels of said at least one unit.
 4. The modular closet of claim 1, wherein at least one unit of said plurality of units further comprises at least one shelf disposed within said substantially hollow interior of said at least one unit.
 5. The modular closet of claim 1, wherein said plurality of stackable units comprises two stackable units, three stackable units, four stackable units, five stackable units, or six stackable units.
 6. The modular closet of claim 1, wherein said proximal end is mounted using at least one mounting device selected from the group consisting of a bracket, a hook, a bolt, a nut, a nail, a dowel, a peg, a screw, adhesive, an interconnecting joint, a magnet, and combinations thereof.
 7. The modular closet of claim 1, wherein at least one unit of said plurality of units further comprises at least one hanging cubby.
 8. The modular closet of claim 7, wherein each unit of said plurality of units is fastened to an adjacent unit of said plurality of units.
 9. The modular closet of claim 1, wherein said stackable units are comprised of solid wood, a wood composite, a laminated wood product, or a combination thereof.
 10. The modular closet of claim 1, wherein said stackable units are configured to be freestanding.
 11. The modular closet of claim 1, further comprising a stabilizing fixture fastened to at least one unit of said plurality of units, said stabilizing fixture configured to secure said at least one unit to a support structure.
 12. A method for constructing a storage structure, comprising: providing a plurality of stackable units, each unit of said plurality of units having a substantially hollow interior defined by a first side panel, a second side panel, a top panel, a bottom panel, a back panel, and a front opening; arranging said plurality of stackable units, wherein each stackable unit of said plurality of stackable units abuts an adjacent stackable unit of said plurality of stackable units, to form a stacked group of stackable units; providing at least one hanging rod having a first end and an opposing second end; attaching said first end of said at least one hanging rod to an outer surface of said stacked group; and attaching said second end of said at least one hanging rod to a first support structure.
 13. The method of claim 12, further comprising the steps of: after said arranging, reversibly fastening adjacent stackable units of said plurality of stackable units together; and after said fastening, securing said stacked group to a second support structure.
 14. The method of claim 12, wherein said first support structure is a wall, a beam, a post, a stud, a second storage structure, or combinations thereof.
 15. The method of claim 12, wherein said attaching said first end and attaching said second end comprise using at least one mounting device selected from the group consisting of a bracket, a hook, a bolt, a nut, a screw, a nail, a dowel, a peg, adhesive, an interconnecting joint, a magnet, and combinations thereof.
 16. The method of claim 12, wherein said arranging comprises stacking said plurality of units inside a storage area.
 17. The method of claim 16, wherein said storage area is selected from the group consisting of an open room, a closet, a garage, an attic, and combinations thereof.
 18. The method of claim 16, wherein said stacking said plurality of units inside a storage area comprises stacking said plurality of units inside a closet, wherein said first support structure comprises an interior side wall of said closet.
 19. The method of claim 16, wherein said stacking said plurality of units inside a storage area comprises stacking said plurality of units in an open room, wherein said first support structure comprises a wall of said room.
 20. A modular closet system, comprising: a stackable unit comprising a first side panel, a second side panel, a top panel, a bottom panel, a back panel, a substantially hollow interior, and a front opening integral with said substantially hollow interior; and at least one external hanging rod having a proximal end and an opposing distal end, said proximal end mounted to an exterior surface of said stackable unit, wherein said distal end is mounted to a first support structure. 